Top press tool

ABSTRACT

Embodiments of the invention generally provide a fixture for assembling an optical component. The fixture generally includes a substantially rigid base member having a measurement aperture formed therein, a pair of upstanding frame members, each of the upstanding frame members having a pivotal mount and a vertical slot formed therein, and a support press slidably positioned within the vertical slot. The fixture may further include a component support assembly positioned below the support press, and a pivot arm connected to the support press at a first end, pivotally connected to the pivot mount at a middle portion, and a screw actuator at a second end.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional patent applicationser. No. 60/422,284 filed Oct. 30, 2002 which is herein incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention generally relate to and apparatus andmethod for assembling optical components. More particularly, embodimentsof the invention relate to an apparatus and method for assembling anoptical source or an optical lens into an optical housing in a power-onstate.

2. Description of the Related Art

Assembly of optical components is generally accomplished via simplemechanical operations that may be automated. Although the automationprovides for increased throughput and accuracy in the assembly process,the components are nevertheless generally tested after the assemblyprocess to determine if the component is within tolerances. Therefore,optical component assembly processes are generally a two step process,wherein the first step is the assembly and the second step, which isconducted in a separate apparatus, is generally an inspection step.

Inasmuch as multiple steps require more resources to manufacturecomponents, is desirable to eliminate the requirement to assemble thecomponent and measure the component in separate apparatuses.

SUMMARY OF THE INVENTION

Embodiments of the invention may generally provide an apparatusconfigured to assemble optical devices, and further, during the assemblyprocess (real time), the apparatus measures input/output signals of theoptical devices to correct optical offsets that may be inherent in themanufacturing process. The apparatus generally includes an outer frameand an inner frame, wherein the inner frame is vibrationally isolatedfrom the outer frame, i.e., the inner frame is isolated from noiseassociated with or encountered by the outer frame. The inner framegenerally supports a work plate configured to receive one of a pluralityof component assembly fixtures thereon, wherein the individual fixturesare each configured for a particular optical component assembly process.The work plate also operates to position the assembly componentsrelative to an optical measurement system, which is used to determineoffset of the components prior to completion of the manufacturingprocess. The optical measurement system includes a camera adapted to)receive an optical signal from an assembled optical device positionedin the assembly fixture. The camera receives light from a split lightpath having a specialized backlight system adapted to enhance theappearance of the optical signal. The output of the camera is fed into adata processing and display system configured to display the output tothe user. The output may generally be presented to the user via adisplay, wherein the display may illustrate the focus of the output,intensity of the output, positioning of the output, and the offset ofthe output. Using the display, the user may adjust the offset of thecomponent before assembly is completed, as well as measure and recordvarious other optical parameters of the component that may be relevantto future component operation, installation, manufacturing, or otherprocesses.

Embodiments of the invention may further provide an apparatus and methodto assemble optical components and measure the resultant performance ofthe components during assembly and adjust the assembly process insitu toprovide an improved optical component. The apparatus and method provideimproved 3D imaging for positional information relative to the outputoptical signal of the component. The optical measurement system isvibrationally separated from a work plate to minimize installationerrors. The apparatus is able to measure a plurality of input and outputsignals to determine the optical device performance during assembly.Position based on optical measurement system focus.

Embodiments of the invention may further provide an apparatus and methodfor measuring the optical offset of an optical component with a Z-Cameraaxis measurement device. The method generally includes loading acomponent shell into a fixture mounted on the measurement apparatus andthen inserting an optical source into the component shell. The opticaloutput of the component is then observed by a camera positioned belowthe component. The camera transmits the image of the optical signal to aprocessing device, i.e., a PC, that displays the position/offset of thedevice to the user. In response to the displayed offset, the user mayadjust physical parameters of the component in order to correct for theoffset prior to final assembly of the component. The correction may beautomated in that the system controller may operate to control a processconfigured to automatically adjust the physical parameters of thecomponent to correct for the offset.

Embodiments of the invention may further provide an automated componentassembly fixture and method configured to press an optical assembly intoa housing/body when used in conjunction with an optical componentinstallation and measurement apparatus. The automated apparatus/methodof the invention generally includes relieving backlash in the assemblysystem by making a movement in the direction of the assembly, checkingfor a signal, adjust the x and y coordinates to obtain the signal in themeasurement plane, determine the quadrant of the signal, adjust the zposition and re-verify the image x and y plane, scan in z to determinethe focus, subtract an empirical number from the z distance and drive tothat distance, take a fine z measurement, calculate the appropriate zdistance, drive to the calculated z distance, and release the assembledpart. This process essentially guarantees a 100% part assembly and focuswithout generating any throwaways as a result of overshoot.

Embodiments of the invention may further provide a component assemblyfixture configured to press an optical assembly into a housing/body whenused in conjunction with an optical component assembly and measuringapparatus. The fixture is based upon a top press-type operation, whereinthe optical assembly is pressed into the housing from the backside(electrical contact side) of the optical assembly. The top pressconfiguration provides for high pressure assembly with great accuracy,and therefore, the focus of the optical assembly may be set withoutovershoot, which conventionally results in rendering the componentunusable. Additionally, the top press provides easy insertion andremoval of components. The physical structure generally includes twoslide pins that capture a pivot point so the pivot point and distallyextending a work bridge may press the optical assembly into thebody/mount. Top press allows for high accuracy press assembly, increasedthroughput, reduced/eliminated throwaways, and easy access for insertionand removal of components.

Embodiments of the invention may further provide a component assemblyfixture configured to press an optical assembly into a housing/body whenused in conjunction with an optical component assembly and measurementapparatus. The fixture is based upon a differential press screw that hastwo opposing thread speeds. Therefore, one side of the differentialpress screw actuates the housing in a positive z direction, while thesecond side of the differential press screw actuates the opticalassembly in a negative z direction. This actuation causes the opticalassembly to be pressed into the housing with great precision using veryfine movements at very high pressure with large circumferential movementof the actuator itself. Thus, the focus of the optical assembly may beset without risking overshoot, which conventionally results in renderingthe component unusable. Additionally, the present invention provides asubstantial improvement in throughput, about 5 times conventionalassembly speeds. The differential screw allows for precise pressing atvery high pressures, which allows for pressing an optical source into ahousing in a one shot-type method without overshooting the focus andrendering the part a throwaway—also without requiring more than onemeasuring step, as with conventional assembly apparatuses.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 illustrates a perspective view of an embodiment of the invention.

FIG. 2 illustrates a partial exploded view of an embodiment of theinvention.

FIG. 3 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention.

FIG. 4 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention having a component therein.

FIG. 5 illustrates a side perspective view of an exemplary cam operatedlaser press assembly fixture of the invention.

FIG. 6 illustrates a side perspective view of an exemplary automated camoperated laser press assembly fixture of the invention.

FIG. 7 illustrates an exemplary fixture of the invention that utilizes adifferential press screw assembly.

FIG. 8 illustrates a sectional view of the differential press screwassembly illustrated in FIG. 7.

FIG. 8 a illustrates a flow diagram of an exemplary method of theinvention.

FIG. 9 illustrates a graphical view of the optical offset measurementprocess.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a perspective view of an embodiment of the invention.The optical component assembly apparatus 100 generally includes asubstantially rigid base member 101 that supports an inner frame member102. Inner frame member 102 is separated from the rigid base member 101via a plurality of cushioning devices 104. The cushioning devices 104,which may be air isolators, for example, are configured to isolate thecomponents attached to inner frame member 102 from any ambient groundnoise that may be received by base member 101. The upper portion ofinner frame member 102 includes an optical component press and measuringassembly 105. Further, the substantially rigid base member 101 may alsosupport an outer frame member 103, which may include storage space forthe mechanical and electronic devices needed to operate the opticalcomponent assembly apparatus 100, while also providing an upper workingsurface for the operators of the apparatus.

More particularly, inner frame member 102 is generally secured to rigidbase member 101 via a plurality of airbag actuators 104. Airbagactuators 104 are essentially an air cushion that is selectively influid communication with a pressurized air source. As such, theinflation of the airbags 104 can be varied as needed. In this invention,the airbags can be used to both isolate the inner frame member 102 andits associated components from vibration, as well as to level the innerframe member 101. Further, as illustrated in FIG. 1, inner frame member102 generally includes a plurality of legs radially extending therefrom,which generally attach to the rigid base member 101 via airbags 104. Theradial extension of the plurality of legs from inner frame member 102provides for a wide and stable base for the operational components ofoptical component assembly apparatus 100, which as will be describedfurther herein. Furthermore, since it is desirable to isolate theworking components of the assembly apparatus 100 from ambient noisesources, in addition to inner frame member 102 being isolated from rigidbase member 101 via airbags 104, the outer frame member 103 is alsoisolated from inner frame member 102. More particularly, although outerframe member 103 may include several components of the optical componentassembly apparatus 100, outer frame member 103 is generally not rigidlysecured or attached to inner frame member 102, and therefore, anyactuation of the outer frame member 103 will not affect the componentassembly and or measuring process taking place within the operationalcomponents of apparatus 100 that are secured to the upper portion ofinner frame member 102.

FIG. 2 illustrates a partial exploded view of an embodiment of theinvention, and more particularly, FIG. 2 illustrates the opticalcomponent assembly apparatus 100 of the invention, wherein the opticalcomponent press and measuring assembly 105 is raised from the innerframe member for better illustration. The optical component press andmeasuring assembly 105 is secured to an upper portion of inner framemember 102 via a second frame member 201. Second frame member 201supports a fixture support 202 on an upper portion thereof. As such, thesecond frame member 201 and fixture support member 200 are rigidlyattached to inner frame member 102. Second frame member 201 also isslidably engaged with a component press and measuring assembly 215 via aZ slide 210. Z slide 210 operates to allow the component press andmeasuring assembly 215 to move in a Z direction with respect to theinner frame member 102, wherein the Z direction is generally defined asvertically with respect to the substantially rigid base member 101.However, Z slide 210 is configured to prevent motion of the componentpress and measuring assembly 215 in any direction other than the Zdirection. Additionally, inasmuch as isolation of the component pressand measuring assembly 215 is an important element of the presentinvention, Z slide 210 may further include a pneumatic neutralizer 209attached thereto, wherein neutralizer 209 is generally configured toapply an upward force to the component press and measuring assembly 215that is calculated to be sufficient to neutralize the gravitationalforce or being exerted thereon.

The remaining components of the press and measuring assembly 215 aresupported by a pair of upstanding frame members 203, wherein theupstanding frame members 203 are attached to a surface of the Z slide210. Therefore, when slide 210 is actuated by the manual actuator 211,which generally operates to move slide 210 in an upward or downwardmotion, the remaining components of the press and measurement assembly215 will also move upward or downward, as they are rigidly attached toslide 210 via frame members 203. However, it is to be noted that slide210 moves relative to frame member 201 and 202, and therefore, movementof slide 210 causes the press and measuring apparatus 215 to moverelative to the remaining components of the invention. Generallyspeaking, the remaining components include an adjustable table 204 andan optical measuring device 207. The adjustable table 204 attaches tothe upper portion of frame members 203, and is configured to linearlymove in both X and Y directions, while preventing movement of table 204in the Z direction. The movement of table 204 may be controlled by twomanual actuators, wherein a first actuator 205 is configured to movetable 204 in the X direction, and the second manual actuator 206 isconfigured to move table 204 in the Y direction. Therefore, embodimentsof the invention essentially provide for movement of table 204 in threedimensions, i.e., X, Y, and Z, via actuation of manual actuators 205,206, and 211, respectively. Therefore, embodiments of the inventionprovide for a table 204 that may be precisely moved in athree-dimensional space with respect to a fixed plate, i.e. plate 202,for the purpose of measuring and/or pressing optical components intooptical housings or other areas.

FIG. 2 also illustrates another feature of the optical componentassembly apparatus 100. More particularly, FIG. 2 illustrates aplurality of air pressure regulators 208, which are generally in fluidcommunication with individual air bags 104. As such, when a force isexerted on an individual side of the leg portions of frame member 102, achange in the air pressure in the corresponding airbags 104 will benoticed in a corresponding one of the pressure regulators 208. Inresponse thereto, the air pressure to the airbags 104 may be increasedand or decreased to maintain frame member 102 in a predeterminedorientation, i.e., to maintain frame member 102 in a verticalorientation, for example. Therefore, embodiments of the invention mayinclude a controller, i.e., a microprocessor type controller, forexample, which may be in electrical communication with air bagregulators 208, and therefore, operate to automatically maintain thepredetermined orientation of frame member 102. Additionally, anotherpressure regulator 208 may be in fluid communication with pneumaticcylinder 209 for the purpose of maintaining slide 210 in essentially azero gravity type situation, i.e., a configuration wherein the cylinder209 is configured to exert an upward force on slide 210 that isequivalent to the weight of the slide.

Optical measuring device 207 includes a camera 225 positioned on a lowerportion thereof. Camera 225 is generally a camera with sufficientresolution to accurately and efficiently capture optical signals fromoptical components being assembled by apparatus 100. An intermediateportion of optical measuring device 207 includes a magnification unit226 that is in optical communication with an intermediate assemblyconfigured to provide backlight to the entire optical measuring device207. The upper portion of optical measuring device 207 may include alens assembly 228 configured to receive optical signals therein andtransmit the optical signals through the entire optical measuring device207 to the camera 225. Optical measuring device 207 is generally mountedwithin press and measuring assembly 105, and more particularly, opticalmeasuring device 205 is generally mounted such that the lens assembly228 is positioned immediately below an aperture formed in movable plate204. Therefore, in this configuration, lens assembly 228 is configuredto view an optical signal generated from an optical component mountedwithin a fixture positioned on upper work plate 202.

FIG. 3 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention. Press assembly 300, which mayalso be termed a press tool, generally includes a substantially rigidbase member 301 that supports the remaining elements of press assembly300. A pair of upstanding support members 302 are attached to basemember 301 in a configuration that provides for a working space betweenthe two support members 302. The inner surfaces of upstanding supportmembers 302 include a vertical channel 310 formed therein, wherein therespective channels 310 formed into the support members 302 arepositioned opposite of each other. Additionally, a central portion ofsupport members 302 includes a recess 311 configured to support apivotally mounted arm 309. A pair of longitudinal apertures are formedinto support members 302, wherein the longitudinal apertures areconfigured to support pivotal securing members 308 therein. Pivotalsupport members 308 are slidably positioned within the apertures and areconfigured to be actuated or pivoted to secure a pivotal mount 305 tosupport members 302. A workpiece support press 303 is positioned betweensupport members 302, and in particular, support press 303 is slidablypositioned within vertical channels 310. As such, support press 303 isconfigured to move only in the direction of channels 310, which isvertical in the present exemplary embodiment. Press assembly 300 furtherincludes a pivotally mounted press arm 309 pivotally mounted to supportmembers 302 via shafts/pivotal mounts 305. Press arm 309 attaches tosupport press 303 at a first end, mounts to support members 302 viapivot mount 305 in a middle portion, and attaches to a screw member 306at a second end. In this configuration screw member 306 may be actuatedto pivotally move press arm 305 such that support press 303 movesvertically within channels 310. Press assembly 300 further includes acomponent mount 307 positioned below support press 303 such that acomponent may be supported on component mount 307 and pressed into ahousing supported within aperture 304.

FIG. 4 illustrates a perspective view of an exemplary cam operated laserpress assembly fixture of the invention having a component therein. Theexemplary press assembly 400 includes components similar to the assembly300 shown in FIG. 3. In particular, press assembly 400 includes a base401, support members 402, press support 403, press arm 405, and screw406. Press assembly 400 also includes a component support 410 mounted atdistal ends to press support 403. Component support 410 is attached topress support 403 such that component support 410 remains stationarywith respect to press support 403. Thus, in this embodiment, a componenthousing having an optical source 404 positioned therein may be placed inpress support 403. The power connections for the optical source 404 aregenerally exposed such that electrical contact may be made with thepower connections during the pressing process. The screw actuator 406may be actuated downward, which pivots the press support 403 upwardtoward the component support 404. This relative movement operates topress the optical source 404 into the housing. Additionally, presssupport 403 includes an aperture formed therethrough, and the apertureis positioned in the optical path of the optical source 404. As such,while the component is being pressed, i.e., while the optical source 404is being pressed into the optical housing, power may be applied to theoptical source 404 and the output of the source may be transmittedthrough the aperture formed into the press support 403 and received by ameasuring device. The measuring device may then use measurements of theoptical source's output to determine if the optical source 404 has beenpressed into the optical housing to an optimal depth, i.e., a closedloop-type control system that presses the optical source 404 to theoptimal or focal point of the device in a single press and measureoperation.

FIG. 5 illustrates a side perspective view of an exemplary cam operatedlaser press assembly fixture or press tool of the invention. The pressassembly 500 includes a base 501, an upstanding support 502, slidablymounted press support member 503, a pivotally mounted press arm 505, anda screw assembly 506. Additionally, a fixed component mount 510 isillustrated. In this embodiment, screw assembly 506 may be actuated todrive a second end of arm 505 upward as a result of pivotal movementabout a pivot point 509. The pivotal movement causes a first end (theend opposite second end that is attached to the press support member503) to move downward. In this manner an optical housing secured withincomponent mount 510 may have an optical component (optical source, lens,or other component) pressed therein by press support member 503 viaengagement of the component with a stationary fixture or component pressmounted to the base 501.

More particularly, in operation, the embodiments of the inventionillustrated in FIGS. 3, 4, and 5 generally operate in the same manner topress an optical component, such as a laser, for example, into anoptical housing. In particular, the press assembly is generallyconfigured to support an optical housing in a face down manner, i.e., ina manner such that the output of the optical component is directedtoward the base plate 401, for example. In this manner the power leadsfor the laser being pressed into the housing are generally extendingupward from the housing having the laser therein such that a powerfixture may be attached to the power leads in order to power the laserduring the pressing operation. As such, the laser is generallyoperating, i.e., emitting an optical signal during the pressing process.However, as noted above, the efficiency and intensity of the opticalsignal is dependent upon the pressed position of the optical source orlaser. Therefore, it is critical that the optical source be pressed to aprecise depth within the optical housing such that the output isoptimized. This optimization is generally dependent upon the opticalsource being pressed to the optimal focal point within the opticalhousing. Further, the base member generally includes an aperturepositioned below the optical housing having the laser pressed therein,such that the optical output of the laser is directed through theaperture. Thus, when the screw assembly is actuated, the press arm movesdownward and presses the activated optical source into the housing whilethe optical signal generated by the optical component is transmitteddownward through the base of the fixture. This signal may then beobserved by the camera positioned there below.

FIG. 6 illustrates a side perspective view of an exemplary automated camoperated laser press assembly fixture or press tool of the invention.The automated press assembly 600 generally includes components similarto the previously discussed press assemblies, however, the adjustment ofthe x, y, and z position of the press and/or camera is accomplished viaan automated process, i.e., without manual adjustment. The pressassembly 600 generally includes a y-axis actuator 601, an x-axisactuator 602, and a z-axis actuator 603. Each of the respectiveactuators are in communication with a system controller configured tocontrol the operation of the actuators. The controller is generallyconfigured to receive input from the camera mounted on the press andmeasurement assembly and actuate each of the respective actuators inorder to obtain an optimal optical parameter. For example, the actuatorsmay be controlled to press a lens into an optical mount to an optimalfocal point via measurement of the output intensity and shape of theoptical output of the component. Similarly, the automated press assembly600 may be configured to press an optical source into an optical housingto an optimal depth via an automated process.

Generally, the automated process includes monitoring the optical outputof the component being assembled via a camera, such as camera 225illustrated in FIG. 2. The camera, or other device configured to measurean output parameter of an optical source, may be in communication with acontroller, such as a micro processor-type controller, for example. Thecontroller is generally configured to compare the output to a preferredor predetermined output, and then adjust the x, y, and/or z positionadjustments in order to adjust the output of the component to be closerto the desired output. The process may continue until the output iswithin an acceptable range, which is generally optimal for thecomponent. The analysis and/or comparison process of the controller maybe conducted in accordance with a software program stored in memory andexecuted on a processor. Generally, the algorithm or comparisonmechanism is configured to compare the contrast of the output of thecomponent to a known acceptable or optimal contrast. More particularly,the output of optical devices is generally a circular or oval shapedoptical footprint. The footprint generally changes in both shape andperimeter contrast as the focus of the component is adjusted. Therefore,the measuring apparatus of the invention may be configured to press anoptical source, such as a laser, into an optical housing whilemonitoring the output of the component. The output will continuallychange in both shape and contrast as the laser is pressed into thehousing. As such, the camera may be configured to observe the output andcompare the shape and contrast measurements of the component to desiredor optimal parameters that are known. The pressing process may then becontrolled in a closed loop manner to press the source to a locationwithin the housing that will generate an optimal output.

FIG. 7 illustrates another fixture or press tool that may be implementedwith the press and measuring assembly of the invention. The pressfixture illustrated in FIG. 7 generally includes a substantially rigidbase 700. A slidably positioned assembly clamp 701 is positioned on anupper side of base member. Clamp 701 is configured to slide into aposition to secure an optical component to a workpiece support 706during the press or measurement operation. Additionally, a pair ofrelease latches are positioned adjacent support 706, wherein the releaselatches 702 are configured to raise an optical component secured to thesupport once the pressing operation is completed. The lower side of base700 generally includes differential press screw assembly 703 thatincludes a screw actuator 705 and a lens press nut 704. The differentialpress screw 703 threadebly engages base 700, and therefore, may beactuated into base 700 via rotational actuation of screw actuator 705.In this configuration a lens or other optical component may bepositioned on the lens nut 705 and pressed into an optical housingsecured on support 706.

FIG. 8 illustrates a sectional view of the differential press screwassembly illustrated in FIG. 7. The differential press screw assemblygenerally includes a hollow interior optical path 810 and an outer screwactuator 801 that has a first annular surface including a first threadedregion 804 formed thereon. Screw actuator 801 further includes a secondannular region having a second threaded region 803 formed thereon. Screwactuator is assembled into the fixture by threadebly engaging a firstinner threaded surface with the first threaded region 804. A distalextending end of the actuator 801, i.e., the end proximate the secondthreaded region, extends into an inner cavity of the fixture, where alens press nut 805 is slidably positioned. Lens press nut 805 includesan outer surface that slidably engages the inner surface of the fixture.Additionally, an inner surface of nut 805 includes a threaded bore 808that is configured to threadebly engage the second threaded region 803of actuator 801. In this configuration, screw actuator may be rotated tocause the lens press nut 805 to extend into an optical component space806. Thus, in operation, a lens to be pressed into an optical componentmay be positioned either on nut 805 or within an optical component thatis positioned or secured within component space 806. With the componentsecured, the screw actuator may be rotated to press the lens into therespective optical housing to a specific depth. The depth may be set bythe mechanical setup of the differential screw, or alternatively, thedepth may be determined through an automated process. For example,embodiments of the invention may utilize the camera assembly 225illustrated in FIG. 2 to analyze the output of the optical componenthaving the lens pressed therein. The analysis process, which will befurther discussed herein, generally includes pressing the lens into thecomponent while simultaneously viewing the optical output of thecomponent. This output may be compared to a desired optical output todetermine if the lens has been pressed into the component to the properdepth, i.e., to the focal point.

In operation, embodiments of the invention provide a method forassembling and/or measuring optical properties of an optical component.The assembly and measurement process may be accomplished real time,i.e., the optical component may be active during the assembly and/ormeasurement processes. For example, assuming that the component beingassembled and/or measured is an optical component having an opticalsource therein, then the optical source may be assembled within anoptical housing with the power to the optical source being on during theassembly process. The assembly process generally includes pressingeither an optical source, i.e., a laser, into a component, oralternatively, pressing an optical component, i.e., a lens, into acomponent already having a source via a press tool (various press toolsand configurations may be used without departing from the scope of theinvention). In this manner, the optical output of the component may bemeasured during the assembly process. Further, the optical output may beused as a control parameter for the assembly process, as the intensity,shape, contrast, and other parameters of the optical output may bemeasured and compared to a desired value in order to determine, forexample, if the optical source is optimally positioned within theoptical housing.

More particularly, FIG. 8 a illustrates a flow diagram of an exemplarymethod of the invention. The methodology illustrated in FIG. 8 a isdirected to an embodiment of the invention wherein an optical source,i.e., a laser for example, is pressed into an optical housing. However,it is to be understood that the present invention is not intended to belimited to this embodiment, as the methodology is generally applicableto assembling various optical components that emit an optical signal.For example, the methodology may be utilized to press a lens into anoptical component while monitoring the output of the component todetermine when the lens is pressed to an optimal point, such as thefocal point, for example. Further, the inventors contemplate thatvarious other optical components may be assembled using the basicmethodology of the invention.

The exemplary method illustrated in FIG. 8 a is generally directed to anembodiment wherein a laser is being pressed into an optical housing.Therefore, the embodiment illustrated in FIG. 8 a is generallyconfigured to press the laser to an optimal distance within the opticalhousing such that the optical output is optimized. The process ofpressing the laser to the desired distance is accomplished by pressingthe laser while observing the output of the component, as the laser ispowered on during the pressing process. The laser is then pressed untilthe output is observed as being optimal, which corresponds to theoptimal press depth. The method generally begins at step 801 wherein alaser is pre-mounted into an optical housing. At this stage the laser isgenerally mounted within the housing, but is mounted such that the lasermay be longitudinally actuated within the housing in order to adjust theposition of the laser relative to other components within the housing.Once the optical sources are mounted within the optical housing, theentire component may be mounted within a palette or fixture configuredto secure the component for the press and measurement operations. Forexample, the optical component may be mounted within a fixture, such asthe exemplary fixtures illustrated in FIGS. 3, 4, 5, 7, or 8. Once theoptical component is secured in the appropriate fixture, the fixture maybe secured to an apparatus configured to press the optical source withinthe optical housing, as well as measure the optical output of thecomponent during the pressing process.

However, prior to initiating any measurement processes, embodiments ofthe invention generally provide for initializing the apparatus forconducting the pressing and measurement processes. For example, steps803 and 804 of FIG. 8 a illustrates initialization steps that aregenerally conducted prior to beginning a press and measurement process,or alternatively, prior to beginning a press and measurement process fora plurality of components, i.e., a batch. The initialization steps 803generally corresponds to the processes associated with centering theworking surface upon which the above-mentioned fixtures will be mountedwith respect to a machine reference center. Further, step 803 may alsoinclude initializing the station to a reference Z plane, i.e.,determining the Z position of the working surface with respect to theother components of the system, or alternatively, with respect to areference Z position. Step 804 further illustrates initializationprocesses, and in particular, illustrates and initialization processthat includes making initialization measurements with a backlight laserin a power off position. Initialization process of the present inventionmay further include initializing control devices and for systems, suchas, for example, software routines, device controllers, power supplies,cameras, lighting equipment, pressure regulators, and other apparatusesor devices that may be used in conjunction with the optical componentassembly and measuring apparatus of the invention. Therefore, theinitialization process is generally configured to initialize the x, y,and z position of the workpiece support relative to the opticalmeasuring equipment. Further, the initialization processes areconfigured to align the respective axes of the apparatus with eachother, i.e., aligning the x and y axes to be exactly perpendicular toeach other, while also positioning the Z axis perpendicular to the x andy axes.

Once the initialization process is complete, and the palette or fixtureis mounted on the working surface of the press and measurement apparatusof the invention, that the method may continue to step 805, wherein theapparatus measures the facet location of the component without the powerbeing applied to the optical source. The measured facet location maythen be recorded by an automated control system in communication withthe apparatus, such as, for example, a microprocessor based controllerconfigured to control the operation of various components of theinvention. In the illustrated embodiment, the microprocessor basedcontroller may include a personal computer configured to receive inputfrom the measuring device, where the input may represent datacorresponding to the measured facet location, and place the input into astorage medium, such as a hard drive or other commonly used computerstorage medium. Thereafter, this input may be accessible to variousother control systems, such that the measured facet location of theparticular component may be used to conduct various other assembly ormodification processes on the particular component in conjunction withthe measurements taken within the press and measuring apparatus of theattention. Once the power off facet location has been measured at step805, the exemplary method of the invention continues to step 806, wherethe optical source of the component being pressed and measured ispowered on. Once the optical source of the component is powered on, themethod continues to step 807. At step 807 an initial measurement istaken of the optical output of the component with the optical sourcepowered on. This initial measurement is generally a rough measurementconfigured to determine if the component is within tolerances. Forexample, if the optical output of the component is extremely misaligned,it may not be possible to correct for the misalignment, and therefore,the component may be discarded. Therefore, embodiments of the inventionprovide an apparatus and method configured to eliminate parts that arenot within an initial tolerance range immediately without expending timeand resources on the assembly and measurement process. As such, thatmethod apparatus of the invention provides an efficient and accurate wayof eliminating bad order parts prior to expending resources onprocessing the invention order parts.

Once the optical device is powered up in step 806, a measurement device,such as a camera or other device configured to receive and determine theposition of the optical signal output from the component beingassembled, may be used to determine both the x and y position of theoptical output relative to a reference point, as well as the thresholdpower of the optical output, as illustrated steps 808 and 809. Themeasurements taken at steps 808 and 809 may be transmitted and stored ina database that is accessible to various systems, as illustrated in itssteps 810 and 811. Once the power on x and y coordinates are determinedand stored in the database, the method continues to step 812 wherein thelaser focus is determined. In this step, the laser focus is generallydetermined through careful selection of the z position of the camerarelative to the output of the optical device. Furthermore, both the xand y positions may be varied during the focus determination, such thatthe field of view of the camera is consistently able to capture theentire optical signal emitted by the optical component. Thus, in orderto determine the laser focus the present invention, the apparatusessentially scans in the z direction looking for a predetermined ordesired contrast that generally corresponds to laser focus, whilemaintaining the contrast invention within the field of view of thecamera via adjustment of the x and y position of the camera or thefixture having the component secured therein. The process of adjustingthe x, y, and z position is represented by step 813.

The data obtained in step 813 is then committed to a database for futureuse, as illustrated in step 814. The method further includes calculatingthe offset of the optical signal emitted from the optical componentposition within the measuring apparatus, as illustrated in step 815.More particularly, the process of calculating the offsets illustrated instep 815 may generally include determining the x coordinate, ycoordinate, and z coordinate with respect to a reference point, plane,or axis of the system, wherein the x, y, and z coordinates generallycorrespond to the position of the optical signal at the location or theoptical signal is in focus, i.e., the focal point. Additionally, step815 includes the process of calculating a pointing angle, wherein thepointing angle generally corresponds to the angle between a horizontalaxis extending from the optical source to a separate axis extending fromthe emission point of the optical source to the point on the referenceplane in the determined z position. Thus, the pointing angle generallycorresponds to the angle between the optimal signal trajectory axis,i.e., the axis upon which the optical signal would travel away from theoptical component if there were zero offset present in the component,and the axis upon which the optical signal actually travels away fromthe optical component. Since these two axes are different, the pointingangle represents the angle between the respective axes.

Once the respective components of the offset are calculated, thecomponents are generally committed to one or more databases, asillustrated in step 816. In the exemplary embodiment illustrated in FIG.8 a, individual databases are set up to receive the individual plane orcomponents, as well as a separate database configured to receive thepointing angle for each component measured in the exemplary apparatus ofthe invention. With the optical offset measured and recorded, the methodof the invention generally continues to step 817, where the opticalcomponent is removed from the fixture or palette of the invention.Thereafter, the optical component may be moved to a separate apparatusconfigured to compensate for the optical offset inherently presentwithin the optical component, wherein the optical offset has beenmeasured and stored in the above noted databases, as illustrated in step818.

Once the optical component is moved to a second machine configured tomechanically adjust the optical offset of the component, as stated instep 818, the second machine may access the previously stored data,i.e., the data obtained at steps 816, 810, 811, and 814, in order todetermine what physical modifications may be made to the component tocorrect for the optical offset. For example, the information obtained instep 815 and stored in step 816 may be used to determine what portionsof the outer diameter of the optical housing/optical component may bemilled in order to counteract for the optical offset of the component.Put simply, the offset information may be used to determine whatportions of the outer mounting surface of the optical component may bemilled or shaved away in order to physically adjust the optical axis ofthe component such that the optical output is aligned with the center ofthe component, i.e., such that the optical offset of the output of thecomponent is removed or at least counteracted via the physicaladjustment of the mounting surfaces of the component, which isillustrated in step 819 and 820. Once the outer portion of the opticalcomponent is machined to adjust for the optical offset measured in theabove noted process, the method may continue to press the laser into thehousing at step 821, mount the optical component on the camera stationat step 822, and then mechanically adjust for the optical housing, i.e.,a bend component, at step 824, in order to finally align the opticaloutput of the optical component. Once the final alignment has been made,the information corresponding to measurements of the optical componentmay be committed to a database at step 825. The information contained inthe database may then be accessed by other component assembly processes,sales processes, test processes, and or any other processes associatedwith optical components such that the exact parameters of the component,i.e., the outer dimensions and the characteristics of the opticaloutput, may be taken into account in subsequent processes.

FIG. 9 illustrates a graphical view of the optical offset measurementprocess 900. The graphical illustration of measurement process 900 isbest illustrated with respect to three reference axes, i.e., x axis 909,y axis 910, and z axis or machine 0 axis 901. The optical signalemitting end of the optical component being measured is generallyrepresented by 902. Therefore, if the optical component to admitting theoptical signal is perfectly aligned, then the optical signal will betransmitted therefrom and intersect the x-y plane at point 911, whereinpoint 911 is positioned directly below point 902. By way of example, ifthe point of optical emission corresponds with the machine 0 axis andthe optical component is perfectly aligned, then the point at which theoptical signal intersects the x-y plane will correspond with theintersection of axis 901, axis 910, and axis 909. When the optical point911 does not correspond with the machine zero point, then the offset ofpoint 911 may be measured, and generally is measured in terms of the xcomponent of the machine offset 904 and the y component of the machineoffset 906. However, regardless of the initial position of point 902,the measuring apparatus and method of the invention may calculate theoptical offset of the component. More particularly, once the opticalcomponent to be measured is positioned within the apparatus of theinvention, the optical component may be powered all on such that the 10optical signal is admitted therefrom. The optical signal, which isgenerally represented by arrow 912 in FIG. 9, propagates towards the x-yplane and intersects the plane at point 903. Since point 903 does notcorrespond with point 911, it is apparent that the optical component hasan offset. Therefore, embodiments of the invention are configured tomeasure the offset between point 903 and point 911, and furthermore,correct for the optical offset between the respective points.

Once point 903 is determined, the method of the present invention maycalculate the x-component 905 of the optical offset, the y-component ofthe optical offset 906, the pointing angle 908, and the z-axiscorrection for the optical offset/focal point. In particular,trigonometric calculations may be used to determine each of the abovenoted in parameters from the measured position of point 903 in themeasurement plane. However, the z-direction offset and the pointingangle are generally not measured parameters, as they need to becalculated from the measured parameters, i.e., the x and y components ofthe measured offset. Further, although the pointing angle is importantto the method of the invention, the calculation of the z-axis offsetcorrection is critical to the future operation of the component. Moreparticularly, as described in the methodology above, the measurementplane generally corresponds to the focal point of the component.However, the focal point of the component as measured corresponds to thefocal point to at the offset, and therefore, once the offset iscorrected, the focal point measured for the component with the offsetwhen the longer be valid for the component with the offset corrected. Byway of explanation, the path of optical signal 912 generally correspondsto the hypotenuse of a triangle consisting of a first side (the zdirection side) and a second side (the reference plane side). Therefore,when the pointing angle is minimized, i.e., when the offset iscorrected, then the hypotenuse generally corresponds with the first sideof the previously mentioned triangle. Since the hypotenuse is alwayslonger than either of the remaining sides of a triangle, it is apparentthat the measured focal point of the optical component with the opticaloffset the will be shorter then the two focal point of the componentwith the optical offset corrected, as when the hypotenuse is swungtoward the first side, it will be longer than the first side. Thus, itis important to calculate and record the z-offset correction, as thisnumber will directly change the previously measured focal point distanceof the component.

In another embodiment of the invention the press and measurementapparatus of the invention may be used to press an optical componentinto an optical housing proximate an optical source. More particularly,the apparatus of the invention may be used to press an optical lens intoan optical housing having an optical source therein. In this type ofpressing operation the lens may be pressed into the optical housingtoward an optical source, such as a laser, for example, while the outputof the component is observed or measured by the apparatus of theinvention. Thus, the pressing operation, i.e., the depth to which thelens is pressed into the housing, may be controlled in accordance withthe optical output of the component as the lens is pressed therein. Moreparticularly, the optical output may be observed in order to press thelens to the optimal focal point of the device via observance of theoptical output. The observance process may include observing and/ormeasuring the intensity, shape, configuration, contrast, and otherparameters of the output and comparing the observed parameters toparameters corresponding to a component that is optimized. Thecomparison process may then be used to control the press operation toinsure that the lens is pressed to the optimal depth, which is generallythe focal point.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A fixture for assembling an optical component, comprising: a substantially rigid base member having a component support fixture positioned thereon; a measurement aperture formed through the component support fixture and the base member; a pair of upstanding frame members, each of the upstanding frame members having a vertical slot formed therein; a component support press slidably positioned within the vertical slot, the component support press being configured to support the optical source in a power-on mode; a pivot mount positioned adjacent the frame members; and a pivot arm connected to the component support press at a first end, pivotally connected to the pivot mount at a middle portion, and a screw actuator at a second end.
 2. The fixture of claim 1, wherein the screw actuator comprises a threaded actuator extending through the second end of the pivot arm to engage a fixed actuator stop member.
 3. The fixture of claim 1, comprising a pivot mount release member positioned above the pivot mount.
 4. The fixture of claim 3, wherein the pivot release member comprises at least two slidably positioned rod members, the rod members being positioned to extend over the pivot mount to secure the pivot arm therein.
 5. The fixture of claim 1, wherein the component support press includes a central aperture formed therein, the central aperture being aligned with the measurement aperture when an optical component is being assembled.
 6. An assembly fixture for optical components, comprising: a component support positioned on a base, the component support having an aperture positioned to transmit an optical signal from a component therethrough to a measuring apparatus; and a pivotally mounted press assembly positioned above the component support, wherein the press assembly is configured to press an optical source into an optical housing while an optical signal emitted from the optical source is measured by the measuring apparatus positioned below the aperture.
 7. The assembly fixture of claim 6, wherein the pivotally mounted press assembly comprises a pivot arm supported at a central portion by a pivot point.
 8. The assembly fixture of claim 7, wherein the pivot arm is attached to a slidable press at a first end and a screw actuator at a second end.
 9. The assembly fixture of claim 8, wherein the slidable press comprises: a pair of upstanding members each having a vertical slot formed into an interior facing surface thereof; and a press member slidably positioned in the vertical slot and attached to first end of the pivot actuator.
 10. The assembly of claim 7, wherein the pivot arm is detachably secured to the assembly.
 11. The assembly of claim 10, comprising a pair of pivot arm securing members slidably extending through upstanding pivot members positioned adjacent the press assembly.
 12. An apparatus for assembling an optical component, comprising: a top press fixture configured to press an optical source into an optical housing, the top press fixture comprising: a base member having an aperture formed therein; a pair of upstanding support members; a press support slidably positioned between the upstanding support members above the aperture; and a pivot arm connected at a first end to the press support, at a middle portion to a pivot mount, and at a second end to a screw actuator, the screw actuator being configured to press the optical source into the optical housing via actuation of the press support; and a sensor positioned below the aperture, the sensor being configured to receive an optical signal emitted from the optical source during a press operation.
 13. The apparatus of claim 12, further comprising a pair of pivot arm securing members slidably positioned within the upstanding members.
 14. A method for pressing an optical source into an optical housing, comprising: positioning an optical housing in a base member of a press pallet; positioning an optical source in a vertically slidable press assembly positioned above the press pallet; pivotally actuating a pivot arm attached to the press assembly at a first end, pivotally attached to a pivot point at a second end, and attached to a screw actuator at a third end, the pivotal actuation of the pivot arm causing the slidable press assembly to press the optical source into the optical housing; and measuring an optical output of the optical source during the pressing operation.
 15. The method of claim 14, comprising controlling the pressing operation in accordance with the measuring step.
 16. The method of claim 15, comprising terminating the pressing operation when the optical source is pressed into the optical housing to the focal point.
 17. The method of claim 15, further comprising comparing an optical output of the optical source to a desired optical output.
 18. The method of claim 14, wherein the optical source is positioned in the optical housing and pivotal actuation of the pivot arm causes the optical source to be pressed to a focal point distance.
 19. The method of claim 14, wherein measuring the optical output of the optical source during the pressing operation comprises positioning a camera to receive an optical signal transmitted through an aperture formed into the base member.
 20. The method of claim 19, wherein measuring comprises comparing the optical signal to a stored optical signal to determine if the optical source has been pressed into the optical housing to an optimal focal point.
 21. The method of claim 19, wherein measuring comprises comparing at least one of an intensity, contrast, and shape of the optical signal to the stored optical signal. 